Skoda Octavia III 2013 Workshop Manual
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Skoda Octavia III 2013 Workshop Manual

1.6/66; 77; 81; 2.0/105; 110; 135 kw tdi cr engine
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Service
Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine
Engine ID
Edition 07.2014
Service Department. Technical Information
CLH
CLH
CKF
A
B
B
CKF
CRV
CUP
C
C
A
CRK
CRM
CUN
B
B
A

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Summary of Contents for Skoda Octavia III 2013

  • Page 1 Service Workshop Manual Octavia III 2013 ➤ Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine Engine ID Edition 07.2014 Service Department. Technical Information...
  • Page 2 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling...

  • Page 3: Table Of Contents

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Contents 00 - Technical data ........... .
  • Page 4 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Assembly overview - piston and conrod ........
  • Page 5 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Summary of components - coolant pipe ........170 Removing and installing the front top coolant pipes .
  • Page 6 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Charge-air system - radiator, leaktightness ........309 Charge air cooling - Summary of components .
  • Page 7 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing rear silencer ........381 Replacing middle or rear silencer .
  • Page 8 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Contents...

  • Page 9: Technical Data

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 00 – Technical data Identification (SRL000718; Edition 07.2014) ⇒ “1.1 Engine number, engine data”, page 1 Engine number, engine data The engine number (“engine identification characters”...
  • Page 10 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Engine identifi‐ CLHB CLHA CKFB CKFC CRVC CUPA CRKB CRMB CUNA cation charac‐ ters Diesel particle filter Balancing shafts Rep.

  • Page 11: Safety Instructions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 3 ⇒ “2.2 Safety measures for working on vehicles with start/stop system”, page 5...
  • Page 12 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Caution ♦ Do not remove fuel hoses from the fuel filter. ♦ Pay attention to the notes ⇒ “2.6 Fuel hoses in the engine compartment”, page 222 ♦...

  • Page 13: Safety Measures For Working On Vehicles With Start/Stop System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note the following if testers and measuring instruments have to be used during a road test: ♦ Always secure the test and measuring devices on the rear seat and have a second person operate them there.

  • Page 14: Repair Instructions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 6 ⇒ “3.2 Foreign bodies in the engine”, page 7 ⇒...

  • Page 15: Foreign Bodies In The Engine

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 which have been stored unwrapped (e.g. on a shelf or in a tool box). ♦ When the system is open: Avoid using compressed air when‐...

  • Page 16: General Instructions For Charge Air System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove V-ribbed belt ⇒ “1.2 Removing and installing poly V-belt”, page 38 – Remove AC compressor from the bracket for auxiliary units ⇒...
  • Page 17 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ♦ Hose clip pliers are recommended to install spring-type clips. ♦ Install hose connections with screw clamps ⇒ “1.6 Hose connections with screw clamps”, page 308 ♦...

  • Page 18: Removing And Installing Engine

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Removing and installing engine trim panel”, page 10 ⇒...
  • Page 19 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Work procedure Note If the stripped engine is replaced after engine removal, the ♦ tightening of the injection unit clamping claws on the new strip‐...
  • Page 20 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -1-, -3-. – Unlock catch -arrows-, remove cover-2-. – Expose coolant hose -2-. – Unlock catches -arrows-, remove top part-1- of air guide.
  • Page 21 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove battery tray -1- ⇒ Electrical System; Rep. gr. 27 . – Press release buttons on the hose -1- for crankcase ventila‐...
  • Page 22 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Raise holding clamps -arrows-, remove coolant hoses from heat exchanger for heating. – Expose the following plug connections and electric cables:...
  • Page 23 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Detach fuel return-flow line -2- and catch the fuel which flows out with a cleaning cloth ⇒ “2.12 Separating push-on couplings”, page 249 Vehicles with radiator versions 1 and 2 –...
  • Page 24 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock catches -arrows-, remove cover-1- for engine com‐ partment E-box. – Unlock catch with a screwdriver -arrow-, pull cover -1- for E- box engine compartment upwards.
  • Page 25 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect front left electrical plug connections at the gear‐ box: Gearbox neutral position transmitter - G701- Reversing light switch - F4- –...
  • Page 26 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Separate plug connection -3-. – Press back B+-pole protection -2- and unscrew B+-cable from the starter magnet switch.
  • Page 27 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Screw out gearbox mount screws -2- by approximately 2 turns. Continued for all vehicles – Screw out screws -arrows- for engine mount by approximately 2 turns.
  • Page 28 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electric plug connection -1- on the control valve for the air conditioning system - N280- compressor.
  • Page 29 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect the plug connection -1- at the exhaust flap control unit - J883- . – Slacken the clamping sleeve -2- and slide it backwards.
  • Page 30 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen clips -arrows-, remove noise insulation -1- for oil sump. Vehicles with four-wheel drive – To reinstall, mark the position of the flexible disk and the angle gearbox flange to each other.

  • Page 31: Securing The Engine To The Assembly Stand

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Tighten engine mount - T10497- with bolt -T10497/1- with screw -1- to around 20 Nm at cylinder block. Use the upper elongated hole “A”...
  • Page 32 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ♦ Engine and gearbox support - VAS 6095- ♦ Lifting device - MP 9-201 (2024A)- ♦ Engine and gearbox support - VW 540- Precondition •...

  • Page 33: Installing Engine

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Installing engine Work procedure Note Observe all safety measures and notes for assembly work on ♦ the fuel supply and injection system, at the charge air system and observe as well the rules for cleanliness ⇒...
  • Page 34 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – If there are no dowel sleeves -A- are available in the cylinder block for centering the engine and gearbox, insert dowel sleeves.
  • Page 35 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Note The gearbox mount for a vehicle with dual clutch gearbox 0CW ♦...
  • Page 36 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Install air filter ⇒ “6.4 Summary of components - air filter”, page 362 – Checking the oil level ⇒ Maintenance ; Booklet Octavia III .

  • Page 37: Assembly Bracket

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Assembly bracket ⇒ “2.1 Assembly overview - assembly mountings”, page 29 ⇒ “2.2 Support the engine in its installed position”, page 31 ⇒...
  • Page 38 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 10 - Screw ❑ replace after removal ❑ Tightening torque and tightening order ⇒ page 31 11 - Screw ❑...

  • Page 39: Support The Engine In Its Installed Position

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Install pendulum support Note Replace screws which have been tightened firmly to a torquing angle. – Tighten screws in steps in the given sequence:...

  • Page 40: Removing And Installing Engine Support

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press release buttons on the hose -1- for crankcase ventila‐ tion, remove hose from cylinder head cover.

  • Page 41: Removing And Installing Pendulum Support

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove top toothed belt guard ⇒ “1.8 Removing and installing top toothed belt guard”, page 45 – Use the spindle - MP9-200/10- for raising and lowering until all screws are accessible.

  • Page 42: Checking And Adjusting The Assembly Bracket

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Checking and adjusting the assembly bracket Checking the assembly bracket Work procedure The following dimensions must be reached: •...
  • Page 43 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • A distance of -a- = 10 mm must be present between engine support -2- and engine mount -1-.

  • Page 44: Crankshaft Group

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 13 – Crankshaft group Removing and installing a V-ribbed belt and a toothed belt ⇒ “1.1 V-ribbed belt - Summary of components”, page 36 ⇒...
  • Page 45 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Poly V-belt ❑ check for wear ❑ mark the direction of ro‐ tation with chalk or a felt- tip pen before removing ❑...

  • Page 46: Removing And Installing Poly V-Belt

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 13 - Screw ❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 14 - Screw ❑ different lengths ⇒...
  • Page 47 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing – Remove the sound dampening system ⇒ Body Work; Rep. gr. 50 . Caution When installing, risk of damage through reversing the rotation direction of an already used V-ribbed belt.

  • Page 48: Removing And Installing Crankshaft-Belt Pulley

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing crankshaft-belt pulley Removing – Remove V-ribbed belt ⇒ “1.2 Removing and installing poly V-belt”, page 38 –...

  • Page 49: Removing And Installing Bracket For Auxiliary Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing bracket for aux‐ iliary units Removing – Remove the generator ⇒ Electrical System; Rep. gr. 27 .

  • Page 50: Summary Of Components - Toothed Belt Guard

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release the screws in the order -6...1-. – Unscrew screws, remove bracket for auxiliary units. Install Installation is performed in the reverse order, pay attention to the...
  • Page 51 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Bottom toothed belt guard ❑ removing and installing ⇒ “1.9 Removing and in‐ stalling bottom toothed belt guard”, page 48...

  • Page 52: Assembly Overview - Toothed Belt Drive

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Assembly overview - toothed belt drive 1 - Screw ❑ replace after removal ❑ Release and tighten us‐...

  • Page 53: Removing And Installing Top Toothed Belt Guard

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 13 - Guide pulley 14 - High pressure pump ❑ Summary of components ⇒ “3.1 Summary of components - high pressure pump”, page 338 15 - Hub ❑...
  • Page 54 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip bracket -3- with fuel hoses. – Release nut -2- and screws -1-. – Lay fuel filter -4- to the side.
  • Page 55 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open heat protection sleeve -1-. – Disconnect electrical plug connection -3- and put the electric cable to one side.

  • Page 56: Removing And Installing Bottom Toothed Belt Guard

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing bottom toothed belt guard Removing Note To simplify the production process in manufacturing plants, ♦...

  • Page 57: Remove The Toothed Belt From The Camshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -arrows-. – Unhook bottom toothed belt guard -1- upwards and remove. Install Installation is performed in the reverse order, pay attention to the...
  • Page 58 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove crankshaft-belt pulley ⇒ “1.3 Removing and installing crankshaft-belt pulley”, page 40 Caution Risk of destruction as a result of the toothed belt pulley jump‐...
  • Page 59 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen screw -arrow- for camshaft toothed belt pulley; to do so, use counterholder - T10172- with adapters -T10172/11- .

  • Page 60: Removing And Installing Toothed Belt

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Then turn the eccentric of the tensioning pulley with the offset screwdriver - T10264- clockwise -arrow- up to the stop and tighten nut -1- by hand.
  • Page 61 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen fixing screw -1- in the camshaft sprocket by half a turn but do not release it.
  • Page 62 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen nut -arrow- for high pressure pump toothed belt pulley by approximately 90°, use counterholder - T10051- to do so.
  • Page 63 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • Tensioning pulley locked with rig tool - T10265- and fixed with nut -1- up to right stop.
  • Page 64 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • Interlock crankshaft with crankshaft arrester - T10490- . • Lock hub of high pressure pump with rig pin - T10492- .
  • Page 65 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen nut -1- for tensioning pulley and remove rig tool - T10265- . Note Sheet peg of the tensioning pulley must engage in the cast ♦...
  • Page 66 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Make sure that the marking on the toothed belt gear is not flush with the rig pin. You may need to correct the position of the toothed belt gear of the high pressure pump by a tooth clock‐...
  • Page 67 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • The locking point of the hub of the high pressure pump is al‐ ways difficult to find again. A slight difference -arrow- does not influence the engine running.
  • Page 68 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 A - Crankshaft arrester - T10490- stud is positioned to the left of the bore: – Turn the crankshaft in the direction of rotation of the engine until the stud -arrow- of the crankshaft arrester engages during this rotary movement in the sealing flange.
  • Page 69 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Tighten fixing screw -1-. Tightening torques ♦ ⇒ “1.6 Summary of components - toothed belt guard”, page 42 ♦...

  • Page 70: Removing And Installing Sealing Flange And Flywheel

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing sealing flange and flywheel ⇒ “2.1 Summary of components - sealing flange belt pulley side”, page 62 ⇒...

  • Page 71: Removing And Installing The Sealing Flange On The Belt Pulley Side

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Sealing flange on the belt pulley side - tightening torque and tight‐ ening order – Tighten screws in steps in the given sequence:...

  • Page 72: Summary Of Components - Gearbox Side Summary Of Components And Flywheel

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Install -T10053/1- guide bushing on the crankshaft stub. Note Pay attention to the use by date on sealant.
  • Page 73 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Screw ❑ replace after removal ❑ 60 Nm + torque a further 90° ( / 4 turn) 2 - Flywheel ❑...

  • Page 74: Removing And Installing Sealing Flange On Gearbox Side

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Installing intermediate plate – Insert intermediate plate on sealing flange -top arrow- and push onto the dowel sleeves -bottom arrows-.
  • Page 75 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Turn the crankshaft at the screw for toothed belt pulley until the crankshaft is positioned on “TDC” as shown in the illustra‐...
  • Page 76 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Assembly of the assembly device - T10134- A - Clamping surface B - Hexagon nut C - Assembly housing...
  • Page 77 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • Locating hole -A- on sender wheel -C- must align with marking -B- on sealing flange. – Place sealing flange with front side facing down on a clean level surface.
  • Page 78 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – When tightening the knurled screws -A- press the sealing flange and sealing lip supporting ring -B- on the surface of the assembly device - T10134- in such a way that the positioning pin can no longer slide out of the rotor hole.
  • Page 79 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 C - Bolt assembly tool - T10134- onto the crankshaft flange: – Move the assembly cup -C- by hand in the -direction of the arrow- until the sealing lip supporting ring -B- rests on the crankshaft flange -A-.
  • Page 80 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Measure distance between crankshaft flange -A- and rotor -B-. • Specified value: Dimension -a- = 0.5 mm –...

  • Page 81: Removing And Installing Flywheel

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Tighten hexagon nut for the assembly device - T10134- to 40 – Checking sender wheel installation position on crankshaft again ⇒...
  • Page 82 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Insert counterholder - MP1-223 (3067)- into the bore on the cylinder block Pos. -B-, loosen flywheel screws.

  • Page 83: Crankshaft, Piston And Conrod

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Crankshaft, Piston and Conrod ⇒ “3.1 Summary of components - crankshaft”, page 75 ⇒ “3.2 Replace the needle bearing in the crankshaft”, page 76 ⇒...

  • Page 84: Replace The Needle Bearing In The Crankshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 8 - Crankshaft ❑ for vehicles with manual gearbox, no needle bearing must be installed; remove needle bearing if nec‐...

  • Page 85: Assembly Overview - Piston And Conrod

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Attach interior extractor to the needle bearing edge -arrow-. – Pull out needle bearing with interior extractor - Kukko 21/2- and countersupport - Kukko 22/1- .
  • Page 86 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Screw ❑ replace after removal ❑ Oil threads and contact surface. ❑ 30 Nm + torque a further 90°...
  • Page 87 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 8 - Piston pin ❑ removing and installing ⇒ “3.4 Removing and installing the piston”, page 82 9 - Piston ❑...
  • Page 88 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Checking ring-to-groove clearance Special tools and workshop equipment required ♦ Feeler gauges – Clean before inspecting the annular grooves of the piston.
  • Page 89 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Measure cylinder at 3 points crosswise in transverse direction -A- and lengthwise -B-. • Maximum deviation from nominal dimension: 0.10 mm.

  • Page 90: Removing And Installing The Piston

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Oil spray nozzle and pressure relief valve Screw with pressure relief valve, 27 Nm Oil spray nozzle (for cooling piston) •...

  • Page 91: Checking Piston Projection In Tdc

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Install piston with piston ring tensioning strap. Fitting position: • Piston ⇒ page 81 • Bearing shells in the conrods ⇒...

  • Page 92: Separating New Conrod

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Identification of the cylinder head gasket ♦ Part number = arrow -1- ♦ Bores arrow -2- (ignore) ♦ Bores arrow -3- Note If different values are measured during the projection measure‐...

  • Page 93: Cylinder Head, Valve Gear

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 15 – Cylinder head, valve gear Removing and installing cylinder head ⇒ “1.1 Assembly overview - cylinder head cover”, page 85 ⇒...

  • Page 94: Removing And Installing Cylinder Head Cover

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 14 - Injection unit ❑ Observe rules for cleanliness ⇒ “3.1 Rules of cleanliness”, page 6 ❑ Summary of components ⇒...
  • Page 95 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew exhaust temperature transmitter 3 - G495- Pos. -2- with a tool from the tool set SW 17 - T10395- and a suitable tool insert.
  • Page 96 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open heat protection sleeve -1-. – Disconnect electrical plug connections -3-, -5-, -6- expose electric wiring loom.

  • Page 97: Replacing Gasket Rings For Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Slacken the screws for the cylinder head cover in the se‐ quence -7 … 1- and release them.

  • Page 98: Summary Of Components - Cylinder Head

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press in the new gasket ring for the injection unit using the driver - 3390- and a short extension -1- from the outside of the cover up to the stop.
  • Page 99 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Cylinder block 2 - Cylinder head gasket ❑ replace after removal ⇒ “1.5 Removing and in‐...
  • Page 100 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 11 - Double screw ❑ Tightening torque Pos. -4- ⇒ “2.2 Summary of components - coolant temperature transmitter”, page 161 12 - Fit pin ❑...

  • Page 101: Removing And Installing Cylinder Head

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Cylinder head - tightening torque and tightening order Note Replace screws which have been tightened firmly to a torquing angle.
  • Page 102 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove front top coolant pipe ⇒ “3.2 Removing and installing the front top coolant pipes”, page 172 –...
  • Page 103 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press release buttons on the hose -1- for crankcase ventila‐ tion, remove hose from cylinder head cover.
  • Page 104 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Vehicles with front-wheel-drive – Press heat protection sleeve to the side, disconnect electrical plug connection -5-. – Loosen hose clamp -3-, remove air guide hose.
  • Page 105 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Raise holding clamps -1- and undo hose clamp -3-, remove coolant hoses. – Release nuts -arrows-, remove coolant pipe.
  • Page 106 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screw -1- for guide pipe for oil dipstick. – Unscrew screws -2-, -3- for intake manifold holder.
  • Page 107 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connections at the glow plugs ⇒ “1.2 Removing and installing glow plugs”, page 421 –...
  • Page 108 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release the cylinder head bolts in the order -1 … 10-. Note A 2nd mechanic is required for removing the cylinder head.
  • Page 109 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Carefully remove old sealant residue from the cylinder head and cylinder block using a chemical sealant remover.

  • Page 110: Checking Compression

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Turn the crankshaft in the direction of rotation of the engine until the stud -arrow- of the crankshaft arrester engages - T10490- during this rotary movement in the sealing flange.
  • Page 111 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connection at the fuel pressure con‐ trol valve - N276- Pos. -2-. – To relieve the fuel pressure in the high pressure accumulator, start engine for a short time.

  • Page 112: Valve Gear

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Valve gear ⇒ “2.1 Assembly overview - valve gear”, page 104 ⇒ “2.2 Replacing camshaft gasket ring”, page 107 ⇒...
  • Page 113 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 7 - Screw ❑ Loosening order ⇒ page 116 ❑ Tightening torque and tightening order ⇒ page 107 8 - Gasket ring ❑...
  • Page 114 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 19 - Camshaft adjuster Caution A thrust washer Pos. -20- is installed between camshaft adjuster and camshaft for secure con‐...

  • Page 115: Replacing Camshaft Gasket Ring

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ oil the contact surfaces before installing 31 - Locking clip ❑ for hydraulic balancing element Camshaft housing - tightening torque and tightening order –...
  • Page 116 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Carefully turn back set screw -arrow- of the extractor -T10443- until a slight resistances noticeable. – Place extractor - T10443- straight, as shown in the illustration, and lock by tightening the set screw -A-.

  • Page 117: Removing And Installing N205 The Camshaft Adjustment Valve 1

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing - N205- the camshaft adjustment valve 1 Removing – Remove air filter ⇒ “6.5 Removing and installing air filter”, page 364 –...
  • Page 118 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Lock hub of the camshaft using the diesel injection pump rig pin - 3359- ; to do so, insert the rig pin into fork -2- of the driver and into the bore behind it -1- in the cylinder head.
  • Page 119 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 the cylinder head cover is removed: • The groove -1- on the rig pin - T10492- must line up with the camshaft housing -2-.

  • Page 120: Removing And Installing The Camshaft Adjusting Valve

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing the camshaft adjusting valve Note If the adjusting valve Pos. -18- ⇒ “2.1 Assembly overview - valve gear”, page 104...
  • Page 121 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Lock the inlet camshaft with rig pin - T10492- . Please note the following when doing so: The cylinder head cover -1- is installed: •...

  • Page 122: Removing And Installing Camshaft Housing

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew adjusting valve -2-. Install Installation is performed in the reverse order, pay attention to the following points: Note Replace gasket ring.
  • Page 123 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 For vehicles with engine identification characters CRKB, CRMB, CUNA – Separate electrical plug connection -2-. Continued for all vehicles –...
  • Page 124 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen screws for camshaft housing in the sequence -18 … 1-. – Unscrew the screws and carefully loosen the camshaft hous‐...
  • Page 125 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note Pay attention to the use by date on sealant. – Cut off nozzle on tube at front marking (∅ of nozzle approx.

  • Page 126: Checking Hydraulic Balancing Elements

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Apply sealant beads -arrow- onto the clean sealing surfaces of the cylinder head as shown in the illustration.

  • Page 127: Removing And Installing Valve Stem Seals

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Test procedure – Start engine and allow to run until the radiator fan has cut in once. – Increase engine speed to about 2500 rpm for 2 minutes and conduct a test drive if necessary.
  • Page 128 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove the camshaft housing ⇒ “2.6 Removing and installing camshaft housing”, page 114 – When installing again, mark the assignment of the roller rocker arms and the hydraulic clearance compensation elements.
  • Page 129 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Insert the impact drift -VAS 5161/3A- into the guide plate and knock off the tightly fitted valve collets using a plastic hammer.
  • Page 130 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Lightly oil sealing lip of the valve stem seal. – Slide the valve stem seal onto the plastic bushing.
  • Page 131 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ♦ Cylinder head tensioning device - VAS 6419- Work procedure – Remove the camshaft housing ⇒ “2.6 Removing and installing camshaft housing”, page 114 –...
  • Page 132 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Continued for all cylinders – Insert the impact drift -VAS 5161/3A- into the guide plate and knock off the tightly fitted valve collets using a plastic hammer.

  • Page 133: Valve Dimensions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 If the valve collets were removed from the assembly cartridge, first of all they must be inserted into the insertion device for valve collets -VAS 5161/18- .

  • Page 134: Checking Valve Guides

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 2.10 Checking valve guides Special tools and workshop equipment required ♦ Universal dial gauge bracket - MP 3-447 (VW 387)- ♦...

  • Page 135: Lubrication

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 17 – Lubrication Removing and installing parts of the lubrication system ⇒ “1.1 Parts of the lubrication system - Summary of components”, page 127 ⇒...
  • Page 136 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Screw ❑ self-locking ❑ replace after removal ❑ 8 Nm 2 - Oil level and oil temperature transmitter - G266- ❑...

  • Page 137: Removing And Installing Oil Level And Oil Temperature Transmitter G266

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 13 - Seal ❑ replace after removal 14 - Fitting sleeve 15 - Cylinder block 16 - O-ring ❑...

  • Page 138: Summary Of Components - Oil Filter Holder

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connection -arrow- at the oil level and temperature transmitter - G266- . – Loosen clips -arrows-, remove noise insulation -1- for oil sump.
  • Page 139 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Oil drain plug ❑ 5 Nm 2 - O-ring ❑ replace after removal 3 - Screw cap ❑...

  • Page 140: Removing And Installing The Oil Filter Holder With The Engine Oil Cooler

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ 20 Nm 14 - Gasket ring ❑ captive, replace if the oil pressure switch has leaks Oil filter housing - tightening torque and tightening order...
  • Page 141 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen hose clamps -arrows- and remove coolant hose. – Raise holding clamp -4-, remove coolant connection fittings.
  • Page 142 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connection -arrow- at the oil pres‐ sure switch - F1- . – Disconnect electrical plug connection -arrow- at the oil pres‐...

  • Page 143: Removing And Installing Oil Sump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note Place a cloth underneath to absorb escaping engine oil. – Unscrew screws in the order -5 ... 1-,remove oil filter housing together with the engine oil cooler.
  • Page 144 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connection -arrow- at the oil level and temperature transmitter - G266- . – Loosen clips -arrows-, remove noise insulation -1- for oil sump.
  • Page 145 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note Pay attention to the use by date on sealant. – Cut off nozzle tube at the front marking (∅ of nozzle approx.

  • Page 146: Removing And Installing Oil Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Apply sealant bead onto the clean sealing surfaces of the oil sump, as shown in the illustration.

  • Page 147: Removing And Installing Oil Pressure Switch F1

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screws -arrows- and remove oil pump -1-. Caution The screw at the pump wheel must not be released.

  • Page 148: Removing And Installing Oil Pressure Switch For Reduced Oil Pressure F378

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Expose coolant hose -2-. – Unlock catches -arrows-, remove top part-1- of air guide. – Release screw left and right -arrow-.

  • Page 149: Removing And Installing Valve For Oil Pressure Control N428

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect plug connection -arrow-. Note Place a cloth underneath to absorb escaping engine oil. – Unscrew oil pressure switch for reduced oil pressure - F378- .

  • Page 150: Testing Oil Pressure

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Separate electrical plug connection -1-. Note Place a cloth underneath to absorb escaping engine oil. – Unscrew screws -2- and remove oil pressure control valve - N428- .

  • Page 151: Cooling

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 19 – Cooling Cooling system ⇒ “1.1 Connection diagram for coolant hoses”, page 143 ⇒ “1.2 Draining and filling coolant”, page 151 ⇒...
  • Page 152 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Cooler for charge air circuit ❑ fill with fresh coolant af‐ ter replacing 2 - Charge air cooler ❑...
  • Page 153 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Vehicles fitted with auxiliary heating Note Blue = large coolant circuit. ♦ Red = small coolant circuit. ♦...
  • Page 154 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 14 - Coolant connection 15 - Gearbox oil cooler ❑ Equipment variants 16 - Coolant thermostat 17 - Engine oil cooler 18 - Coolant radiator ❑...
  • Page 155 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Cooler for charge air circuit ❑ fill with fresh coolant af‐ ter replacing 2 - Charge air cooler ❑...
  • Page 156 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Cooler for charge air circuit ❑ fill with fresh coolant af‐ ter replacing 2 - Charge air cooler ❑...
  • Page 157 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1.1.3 Connection diagram for coolant hoses (engine identification characters CRKB, CRVC, CRMB, CUNA) Note Blue = large coolant circuit.
  • Page 158 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 13 - Coolant connection 14 - Gearbox oil cooler ❑ Equipment variants 15 - Coolant thermostat 16 - Engine oil cooler 17 - Coolant radiator ❑...

  • Page 159: Draining And Filling Coolant

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ The fitting position is not defined, therefore the coolant hose must not be unclipped with the hose clamp...
  • Page 160 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Vehicles with radiator version 1 – Raise holding clamp -arrow-, remove bottom left coolant hose from radiator, allow coolant to drain.
  • Page 161 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Raise holding clamps -1-, -2-, remove coolant hoses from charge air circuit cooler, allow coolant to drain.
  • Page 162 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Vehicles with radiator version 2 – Connect coolant hose with quick coupling -1- to radiator bot‐ tom right ⇒...
  • Page 163 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Screw the adapter for cooling system testing device - V.A.G 1274/8- to the coolant expansion tank. – Assemble cooling system charge unit - VAS 6096- onto the adapter -V.A.G 1274/8- .
  • Page 164 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open valve -A-. • The vacuum pump in the cooling system draws the coolant out of the coolant reservoir -VAS 6096- and fills the cooling sys‐...

  • Page 165: Checking Cooling System For Leaks

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Checking cooling system for leaks Special tools and workshop equipment required ♦ Cooling system tester - V.A.G 1274 B- ♦...
  • Page 166 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐ ered connecting hose to the cooling system testing device - V.A.G 1274 B- .

  • Page 167: Coolant Pump And Coolant Thermostat

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Coolant pump and coolant thermo‐ stat ⇒ “2.1 Summary of components - coolant pump and coolant ther‐ mostat”, page 159 ⇒...
  • Page 168 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - O-rings ❑ replace after removal ❑ Moisten with coolant 2 - Inlet connections 3 - O-ring ❑...

  • Page 169: Summary Of Components - Coolant Temperature Transmitter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 17 - Coolant thermostat housing 18 - O-ring ❑ replace after removal ❑ Moisten with coolant 19 - Coolant thermostat ❑...

  • Page 170: Summary Of Components - Electric Coolant Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Summary of components - electric coolant pump Charge air cooler pump - V188- Version 1, heating backup pump...

  • Page 171: Removing And Installing Coolant Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Clamp 2 - Screw ❑ 23 Nm 3 - Charge air cooler pump - V188- ❑ removing and installing ⇒...

  • Page 172: Removing And Installing Coolant Thermostat

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connection -2-, expose electric ca‐ ble. – Unscrew screws -arrows-, remove coolant pump -1-.

  • Page 173: Removing And Installing Coolant Valve For Cylinder Head N489

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock catch peg in direction of arrow -B- (from the top using a screwdriver). – Turn and pull off connection fittings -1- in arrow direction -A-.

  • Page 174: Testing Coolant Thermostat

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Testing coolant thermostat – Heat up the removed coolant regulator in a water bath. Start of opening End of opening Opening stroke 87 ±...

  • Page 175: Removing And Installing Charge Air Cooler Pump V188

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Separate electrical plug connection -1-. – Unscrew double screw -2-, remove coolant temperature trans‐ mitter - G62- .

  • Page 176: Removing And Installing The Heating Backup Pump V488

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect plug connection -3-. Note Place a cloth below to absorb leaking coolant. – Disconnect coolant hoses with hose clamps -MP7-602 (3094)- .
  • Page 177 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Separate electrical plug connection -3-. Note Place a cloth below to catch any leaking coolant. – Disconnect coolant hoses with hose clamps -MP7-602 (3094)- .

  • Page 178: Coolant Pipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Coolant pipes ⇒ “3.1 Summary of components - coolant pipe”, page 170 ⇒ “3.2 Removing and installing the front top coolant pipes”, page ⇒...
  • Page 179 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Nut ❑ 10 Nm 2 - Coolant pipe - front right ❑ removing and installing ⇒ “3.5 Removing and in‐...

  • Page 180: Removing And Installing The Front Top Coolant Pipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ removing and installing ⇒ “3.6 Remove and install the left coolant pipes”, page 178 18 - Screw ❑...

  • Page 181: Removing And Installing The Front Bottom Coolant Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip bracket -1- with fuel hoses. – Unscrew screws -arrows-. – Loosen hose clamp -3-, remove coolant hose.
  • Page 182 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -arrows-. – Loosen hose clamp -2-, remove air guide pipe -1-. For vehicles with engine identification characters CLHA, CLHB, CKFB, CKFC, CUPA, CRVC –...

  • Page 183: Removing And Installing The Front Left Coolant Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen hose clamp -1-, remove coolant hose. – Release screw -4-. – Pull off coolant pipe bottom front -3- and remove, do not dam‐...
  • Page 184 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Expose coolant hose -2-. – Unlock catches -arrows-, remove top part-1- of air guide. – Release screw left and right -arrow-.

  • Page 185: Removing And Installing The Front Right Coolant Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Raise holding clamp -1-, remove coolant connection fittings. – Release screw -2-. – Loosen hose clamps -arrows-, remove coolant hoses.

  • Page 186: Remove And Install The Left Coolant Pipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen hose clamps -1-, -4-, -6-, remove coolant hoses. – Release nut -5- and screw -2-. – Expose coolant hoses -3-, remove front right coolant hose.

  • Page 187: Removing And Installing The Rear Coolant Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – remove lock washer -arrow-. Vehicles with coolant hoses left version 1 – Expose electric wiring loom -1-.

  • Page 188: Removing And Installing The Rear Right Coolant Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ♦ Catch pan , e.g. -VAS 6208- ♦ Hose clip pliers - VAS 6340- ♦ Hose clip pliers - VAS 6362- Removing –...
  • Page 189 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing Note Fit all heat protection sleeves on again in the same place when installing. – Remove engine cover ⇒...
  • Page 190 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press release buttons on the hose -1- for crankcase ventila‐ tion, remove hose from cylinder head cover.
  • Page 191 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press heat protection sleeve to the side, disconnect electrical plug connection -5-. – Loosen hose clamp -3-, remove air guide hose.
  • Page 192 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen hose clamp -1-, remove coolant hose. – Unscrew double screw -2- and screw -3-, remove rear right coolant pipe.

  • Page 193: Radiator And Radiator Fan

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Radiator and radiator fan ⇒ “4.1 Parts of the cooling system fitted to body”, page 185 ⇒ “4.2 Summary of components - fan shroud and radiator fan V7 ”, page 190...
  • Page 194 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 11 - Cooler for charge air circuit ❑ removing and installing ⇒ “4.4 Removing and installing radiator”, page 191 12 - Condenser ❑...
  • Page 195 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 4.1.2 Radiator version 2 1 - Coolant radiator ❑ removing and installing ⇒ “4.4 Removing and in‐ stalling radiator”, page 191 ❑...
  • Page 196 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Connect coolant hose with quick coupling – Remove old O-ring -2- in coolant hose -3-. – Moisten new O-ring with coolant and insert into coolant hose.
  • Page 197 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 11 - Rubber bearing ❑ for radiator 12 - O-ring ❑ replace after removal ❑ Moisten with coolant 13 - Coolant hose ❑...

  • Page 198: Summary Of Components - Fan Shroud And Radiator Fan V7

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Summary of components - fan shroud and radiator fan - V7- 1 - Screw ❑ 5 Nm 2 - Fan shroud ❑...

  • Page 199: Summary Of Components- Fan Shroud And Radiator Fan V7 And Radiator Fan 2 V177

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Summary of components- fan shroud and radiator fan - V7- and radiator fan 2 - V177- 1 - Screw ❑...
  • Page 200 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -1-, -3-. – Unlock catch -arrows-, remove cover-2-. – Expose coolant hose -2-. – Unlock catches -arrows-, remove top part-1- of air guide.
  • Page 201 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Raise holding clamp -arrow-, remove bottom left coolant hose from radiator. – Raise holding clamps -1-, -2-, remove coolant hoses from charge air circuit cooler.
  • Page 202 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note If the fuse breaks, you will not need to replace the radiator bearing -1-. Replace the fuse with a special fuse -3- ⇒ ETKA - Electronic Catalogue of Original Parts .

  • Page 203: Removing And Installing Fan Shroud

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock catches on the radiator -1- for the charge air circuit arrows -A- – Remove charge air circuit radiator from coolant radiator -2- arrow -B-and unhook arrow -C-.

  • Page 204: Removing And Installing Radiator Fans V7 And V177

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing radiator fans - V7- and -V177- Removing Note All cable straps should be fitted on again in the same place when installing.

  • Page 205: Fuel Supply System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 20 – Fuel supply system Measures in case of misfuelling Note Fuel lines are secured with quick-release couplings ♦...
  • Page 206 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip cover -1- for closing flange with the disassembly wedge - 3409- on the retaining tabs -arrows-.

  • Page 207: Step 2, The Engine Was Not Started With Incorrect Fuel

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect fuel return-flow line -2- at the closing flange ⇒ “2.12 Separating push-on couplings”, page 249 – Connect connecting line - VAS 6551/1- of the pressure gauge to the fuel return-flow line.

  • Page 208: Step 3, Metal Swarfs Are Present In The Fuel Delivery Unit And The Fuel Tank

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip sealing grommet -1- downwards from the cover -2-. – Guide the cover -2- backward at the electric wiring loom -3-.

  • Page 209: Step 4, No Metal Swarfs Are Present In The Fuel Delivery Unit And The Fuel Tank

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Vehicles fitted with auxiliary heating – Check the fuel line between the fuel tank and dosing pump - V54- for swarfs.

  • Page 210: Step 5, Metal Swarfs Are Present In The High Pressure Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew the screws -arrows- and carefully remove the fuel dosage valve - N290- -A- from the high pressure pump.
  • Page 211 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Screw in screws -arrows- only by hand. – Tighten the screws in two stages: Stage Screws Tightening torque...

  • Page 212: Removing And Installing Parts Of The Fuel Supply System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing parts of the fuel supply system ⇒ “2.1 Fuel tank with component parts - Summary of compo‐...
  • Page 213 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Screw cap ❑ Pull until it can be heard clicking into place ❑ with securing to prevent...
  • Page 214 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ 20 Nm + torque a further 90° ( / 4 turn) 13 - Bracket ❑ For fuel pump control unit - J538- ❑...
  • Page 215 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Screw cap ❑ Pull until it can be heard clicking into place ❑ with securing to prevent...
  • Page 216 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ 20 Nm + torque a further 90° ( / 4 turn) 13 - Support ❑ For fuel pump control unit - J538- ❑...
  • Page 217 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Fitting location of the fuel delivery unit • Arrow -3- at the fuel tank must show marking -2- at the lock...
  • Page 218 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Screw cap ❑ close by turning until it audibly locks into place ❑ with securing to prevent...
  • Page 219 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 12 - Circlip ❑ for heat shield 13 - Heat shield ❑ check for firm seating 14 - Connected fuel hoses ❑...

  • Page 220: Fuel Delivery Unit - Summary Of Components

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Fuel line at the fuel delivery unit Fuel feed line Fuel return-flow line Fuel line to the dosing pump - V54-...
  • Page 221 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Fuel delivery unit ❑ With fuel system pres‐ surisation pump - G6- ❑ electrical testing of the...
  • Page 222 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 7 - Electrical plug connection ❑ for fuel system pressurisation pump - G6- 8 - Electrical plug connection ❑...
  • Page 223 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ after installing a new fuel delivery unit it will be necessary to unscrew the screw plug from the connection on the fuel delivery unit in order to connect the fuel line of the auxiliary heating ❑...
  • Page 224 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 12 - Electrical plug connection ❑ for sender for fuel gauge display - G- 13 - Electrical plug connection ❑...

  • Page 225: Fuel Filter - Summary Of Components

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Fuel filter - Summary of components 1 - Fuel filter - bottom part with integrated bracket ❑ removing and installing ⇒...

  • Page 226: Drain Fuel Filter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 10 - Fuel return-flow hose ❑ Risk of damage to the fuel tank high pressure pump ❑ Observe the instructions for fuel hoses in the engine compartment ⇒...
  • Page 227 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing Note Safety precautions when working on the fuel supply system ♦ ⇒ “2 Safety instructions”, page 3 Observe rules for cleanliness ♦...
  • Page 228 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Equipment variant with water level sender - G63- : Disconnect the electrical plug connection at the water level sender -1-.
  • Page 229 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Equipment variant with water level sender - G63- : Disconnect the electrical plug connection at the water level sender -1-.

  • Page 230: Fuel Hoses In The Engine Compartment

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Fuel hoses in the engine compartment Note Fuel hose supports at fuel filter -1-, at fuel temperature trans‐...

  • Page 231: Extract Fuel From The Fuel Tank

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Extract fuel from the fuel tank ⇒ “2.7.1 Emptying fuel tank when fuel pump is intact”, page 223 ⇒...
  • Page 232 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect the fuel extraction device - VAS 5190- with the adapt‐ er for the fuel extraction - VAS 5190 /3- to the fuel feed line.
  • Page 233 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open tank flap unit -2-. – Clean the area around the fuel filler neck. – Unscrew the cap -1- for the fuel filler neck.
  • Page 234 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Caution To prevent large quantities of fuel from leaking when removing the fuel delivery unit, the fuel tank must not be filled to more than a maximum of / 3 .
  • Page 235 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Continued for all vehicles – Push up catch -2- in arrow direction -A-. – To do so, reach between bottom plate and fuel tank with a finger.
  • Page 236 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Carefully lift out fuel delivery unit flange -3-. – Remove gasket -1- and raise the fuel delivery unit flange slightly higher.
  • Page 237 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip cover -1- for the right closing flange with the disassem‐ bly wedge - 3409- on the retaining tabs -arrows-.
  • Page 238 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect fuel line -1- at the closing flange ⇒ “2.12 Separating push-on couplings”, page 249 – Disconnect fuel return-flow line -2- at the closing flange ⇒...
  • Page 239 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip cover -1- at retaining tabs -arrows-, using removal wedge - 3409- . – Unclip sealing grommet -1- downwards from the cover -2-.

  • Page 240: Removing And Installing Fuel Delivery Unit

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Carefully remove the closing flange -2- on the left together with the suction jet pump -1- from the fuel tank opening a little.
  • Page 241 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip cover -1- for the right closing flange with the disassem‐ bly wedge - 3409- on the retaining tabs -arrows-.
  • Page 242 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove fuel return line -1-, -2- from the closing flange ⇒ “2.12 Separating push-on couplings”, page 249 Vehicles fitted with auxiliary heating –...
  • Page 243 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Pull sealing flange -3- slightly out of the fuel tank opening. – Remove gasket ring -1- from fuel tank opening.
  • Page 244 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – The peg -2- at the closing flange -1- must be located against arrow -3- at the fuel tank.
  • Page 245 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ♦ Disassembly wedge - 3409- ♦ Key - T30101 (3087)- Precondition • The fuel tank must not be more than / 3 full.
  • Page 246 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock electrical plug connections -1-, -2- on closing flange to unlock the connector lock. Vehicles fitted with auxiliary heating –...
  • Page 247 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Pull sealing flange -3- slightly out of the fuel tank opening. – Remove gasket ring -1- from fuel tank opening.
  • Page 248 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Reach into the fuel tank through the opening, unlock the de‐ livery unit from the locking mechanisms -2- and -3- and re‐...
  • Page 249 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Install new gasket ring -1- for closing flange while dry. – Coat inner side of gasket ring -1- with fuel.

  • Page 250: Removing And Installing Misfuelling Protection

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect connectors -1- and -2-. – If present, unhook the electrical plug connection -3- for dosing pump of the auxiliary heating - V54- on the closing flange.
  • Page 251 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Insert circlip pliers into both lock ring openings -arrow-. – Turn locking ring anticlockwise by approximately 25°.

  • Page 252: Deactivate Misfuelling Protection

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Place misfuelling protection in the fuel filler neck. • The peg at the misfuelling protection must reach into the groove on the fuel filler neck -arrows-.

  • Page 253: Removing And Installing The Sender For Fuel Gauge Display

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove the catches marked in red at the marked positions -arrows-. Note It must be possible to open misfuelling protection closing flap of misfuelling without it becoming hooked.
  • Page 254 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 2.11.2 Removing and installing fuel gauge sender 2 - G169- Special tools and workshop equipment required ♦ Disassembly wedge - 3409- ♦...
  • Page 255 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock electrical plug connections -2- from left closing flange, and remove. – Unlock electrical plug connections -1- and -3- from closing flange, and disconnect.
  • Page 256 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock and detach the connector -3- at unit -2-. – Thread out the electrical cables. – Unlock the fuel gauge sender 2 - G169- -1- from the unit -2-.

  • Page 257: Separating Push-On Couplings

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Arrow -3- at the fuel tank must point to marking -2- on the closing flange -1-. Caution Risk of leakage.
  • Page 258 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 WARNING Fuel supply line is pressurised. Wear safety goggles and safety clothing, in order to avoid injuries and skin contact with fuel.
  • Page 259 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press the push-fit coupling -1- in direction of arrow -A-. – Press the release buttons and remove the push-fit coupling -1- from the fuel line -2- in direction of the arrow -B-.
  • Page 260 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Variant 3 Quick coupling with front release button -arrow-. – Press release button -arrow- and pull push-on connectors off.

  • Page 261: Removing And Installing The Fuel Tank

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Variant 7 Quick coupling -1- with release buttons -2- right and left. – Press push-on coupling -1- in direction of arrow -A- and hold pressed.
  • Page 262 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip sealing grommet -1- downwards from the cover -2-. – Guide the cover -2- backward at the electric wiring loom -3-.
  • Page 263 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -1-, -2- for fuel filler neck. – Remove the rear silencer ⇒ “1.4 Removing and installing rear silencer”, page 381 –...
  • Page 264 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – As shown in the illustration, place the engine and gearbox jack - V.A.G 1383 A- under the vehicle for support purposes and support the fuel tank.
  • Page 265 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -2-, -4- and -6-. Note To provide a clearer illustration, the fuel tank is shown without ♦...
  • Page 266 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Ensure the plug connection fits tightly: • The plug -2- on the metal plate ring -3- must be pushed on firmly.
  • Page 267 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip cover right -1- at retaining tabs -arrows-, using removal wedge - 3409- . – Unclip sealing grommet -1- downwards from the cover -2-.
  • Page 268 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip sealing grommet -1- downwards from the cover -2-. – Guide the cover -2- backward at the electric wiring loom -3-.
  • Page 269 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Detach the fuel feed line -1- and the fuel return-flow line -2- ⇒ “2.12 Separating push-on couplings”, page 249 Vehicles fitted with auxiliary heating –...
  • Page 270 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew the screws -1- to -5-. Note To provide a clearer illustration, the fuel tank is shown without ♦...

  • Page 271: Removing And Installing Fuel Pump Control Unit J538

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • The plug -2- on the metal plate ring -3- must be pushed on firmly. • The contact peg -1- must be hung on the fuel tank -4- and secured with the spacer bush -5-.
  • Page 272 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Push up fixing catch -2- with a finger between the bottom plate and the fuel tank arrow -A-.

  • Page 273: Check The Suction Jet Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 2.15 Check the suction jet pump The fuel tank consists of a left and right chamber. In order to pump...
  • Page 274 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note If necessary drain the fuel tank ♦ ⇒ “2.7 Extract fuel from the fuel tank”, page 223 Safety precautions when working on the fuel supply system ♦...
  • Page 275 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Push up catch -2- in arrow direction -A- - to do so, reach be‐ tween bottom plate and fuel tank with a finger..
  • Page 276 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Lift the closing flange -3- carefully out of the fuel tank opening. – Remove gasket ring -1- from fuel tank opening.
  • Page 277 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove and disconnect the drive jet line -1-; to do so, press the release at the connection ⇒...
  • Page 278 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open lock ring with the wrench - T30101 (3087)- . Rep. gr.20 - Fuel supply system...
  • Page 279 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Carefully raise closing flange -2- and remove it from the fuel tank opening. Note Remove gasket ring -3- from fuel tank opening.
  • Page 280 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Fit the suction jet pump to the fuel gauge sender 2 - G169- , to do so, bend the retaining lugs -arrows- one after the other, and insert the suction jet pump.

  • Page 281: Inspecting Fuel Pump G6

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Tighten lock ring with wrench - T30101 (3087)- to 110 Nm. – Mount all fuel lines and connectors to the closing flanges on both sides.
  • Page 282 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note The vehicle must be refuelled with diesel fuel corresponding ♦ to the season. Summer diesel can sometimes coagulate at low winter temperatures.
  • Page 283 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Insert connecting nipple - VAS 6551/5-1- in the feed line -1- and secure using a clamp. – Connect the hose line - VAS 6551/2- between connecting nip‐...
  • Page 284 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove fuel feed line -1- ⇒ “2.12 Separating push-on couplings”, page 249 – Connect hose line - VAS 6551/2- between the fuel feed line from the fuel tank and connection -B- from the pressure gauge - VAS 6551- .
  • Page 285 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip cover -1- at retaining tabs -arrows-, using removal wedge - 3409- . – Unclip sealing grommet -1- downwards from the cover -2-.
  • Page 286 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock fuel feed line -1- on closing flange and pull off ⇒ “2.12 Separating push-on couplings”, page 249 –...
  • Page 287 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Check that all hose connections are connected -arrows-. If no fault is found – Replace fuel delivery unit ⇒...
  • Page 288 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note The vehicle must be refuelled with diesel fuel corresponding ♦ to the season. Summer diesel can sometimes coagulate at low winter temperatures.
  • Page 289 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Insert connecting nipple - VAS 6551/5-1- into fuel feed line and secure using a clamp. – Connect the hose line - VAS 6551/2- between connecting nip‐...
  • Page 290 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Set primary pressure at setting wheel -arrow- by turning pres‐ sure control valve - VAS 6551/6- .
  • Page 291 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect hose line - VAS 6551/2- to the fuel feed line from the fuel tank. – Connect the hose line - VAS 6551/2- at the connection -A- of the pressure gauge (Diesel) - VAS 6551- .
  • Page 292 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unclip sealing grommet -1- downwards from the cover -2-. – Guide the cover -2- backward at the electric wiring loom -3-.

  • Page 293: Check Sender For Fuel Gauge Display G

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Make sure that the shut-off tap -C- is closed at the pressure gauge - VAS 6551- -1-.
  • Page 294 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connections -2- on the closing flange, thereby unlocking the plug lock. Sender for fuel gauge display - G- installed Note To achieve a precise indication of the resistance with a “full fuel...
  • Page 295 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Sender for fuel gauge display - G- removed Note When testing resistance values with “fuel tank full” or “fuel tank ♦...

  • Page 296: Accelerator Mechanism

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Accelerator mechanism ⇒ “3.1 Assembly overview - accelerator module ”, page 288 ⇒ “3.2 Removing and installing accelerator module”, page 288...
  • Page 297 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connections -2- on the accelerator pedal module, thereby pressing the release upwards. – Release screw -1-.

  • Page 298: Turbocharging/Supercharging

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 21 – Turbocharging/supercharging Charge-air system - exhaust gas tur‐ bocharger ⇒ “1.1 Exhaust gas turbocharger with component parts - Sum‐...
  • Page 299 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 8 - Heat shield 9 - O-ring ❑ replace after removal 10 - Pulsation dampener ❑ Observe part number ⇒ ETKA - Electronic Catalogue of Original Parts 11 - Screw ❑...

  • Page 300: Removing And Installing Exhaust Gas Turbocharger

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 27 - Ribbed bolt ❑ 14 Nm 28 - Gasket rings ❑ replace after removal Bracket for exhaust gas cleaning module - tightening torques and tightening order –...
  • Page 301 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Caution In case of mechanical damage to the exhaust gas turbocharg‐ er, e.g. damage of the compressor wheel, it is not sufficient to only replace the exhaust gas turbocharger.
  • Page 302 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Left-hand drive – if a vacuum hose is present: Remove it -arrow- and lay to the side. – Press release buttons on the hose -1- for crankcase ventilation and remove from cylinder head cover.
  • Page 303 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open heat protection sleeve -1-. – Take electrical plug connection-5 - out of the holder, discon‐ nect and expose electric cable.
  • Page 304 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen screw -1- and remove screw clamp. – Slacken the double screw -2-, lay coolant pipe backwards slightly.
  • Page 305 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws 1-…4- and remove bracket for diesel particle filter. – Release screws -arrows- and remove heat shield -1-.
  • Page 306 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew nuts -arrows- and remove the exhaust gas turbo‐ charger with exhaust manifold from the cylinder head.
  • Page 307 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ♦ Socket insert XZN 10 - T10501- Caution In case of mechanical damage to the exhaust gas turbocharg‐...
  • Page 308 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Press release buttons on the hose -1- for crankcase ventilation and remove from cylinder head cover. – Disconnect vacuum hoses on the air guide pipe -arrows-.
  • Page 309 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screws -arrows- and remove heat shield -1-. – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 310 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew nuts -arrows- and detach the exhaust gas turbo‐ charger with exhaust manifold from the cylinder head, and remove from the top.
  • Page 311 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing – Remove engine cover ⇒ “1.1 Removing and installing engine trim panel”, page 10 Version 1 – Disconnect the electrical plug connection -3- from the position sender for charge pressure regulator - G581- .
  • Page 312 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Version 1 – Hook in the control rod at the adjuster lever, attach the pres‐ sure box, and turn in the screws -1- as far as they can go by hand.
  • Page 313 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect the hand vacuum pump - VAS 6213- to the pressure box -arrow-. Caution Risk of damage to the pressure box from excessive vacuum.

  • Page 314: Connection Diagram For Vacuum Hoses

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Put the sliding ring -1- of the hand vacuum pump - VAS 6213- into position -B- to ensure the pressure box is vented until the pressure reaches the ambient pressure.

  • Page 315: Checking Vacuum System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Vacuum line 2 - Non-return valve ❑ Check fitting position ❑ the positive side points to the cylinder head cov‐...

  • Page 316: Hose Connections With Screw Clamps

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – If no vacuum can be created or the vacuum drops immediately with the hand vacuum pump - VAS 6213- , check hand vacuum pump and connecting hoses for leaks.

  • Page 317: Charge-Air System - Radiator, Leaktightness

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Charge-air system - radiator, leak‐ tightness ⇒ “2.1 Charge air cooling - Summary of components”, page 309 ⇒ “2.2 Removing and installing charge pressure sender G31 ”, page 311 ⇒...
  • Page 318 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 14 - Seal ❑ replace after removal 15 - Supports ❑ for throttle valve control unit - J338- 16 - Intake air temperature transmitter - G42- ❑...

  • Page 319: Removing And Installing Charge Pressure Sender G31

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing charge pres‐ sure sender - G31- Removing – Remove engine cover ⇒ “1.1 Removing and installing engine trim panel”, page 10 –...
  • Page 320 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect adapter - V.A.G 1687/11- with -V.A.G 1687/15- to the exhaust gas turbocharger. – Connect testing device for charge-air systems - V.A.G 1687- to adapter.
  • Page 321 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect the pneumatic hose -1- (pneumatic support) to tester for charge air system. Note If there is water in the inspection glass, drain water via the drain plug -6-.

  • Page 322: Mixture Preparation - Injection

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 23 – Mixture preparation - injection Diesel direct injection system - fitting location, system overview ⇒ “1.1 Installation location overview - fuel injection system”, page ⇒...
  • Page 323 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Coolant valve for cylinder head - N489- ❑ Fitting location ⇒ page 317 2 - Injection units ♦...
  • Page 324 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 12 - Intake air temperature transmitter - G42- ❑ Summary of components ⇒ “6.1 Assembly overview - intake manifold”, page 355 13 - Control valve for fuel pressure - N276- ❑...
  • Page 325 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Electrical plug connections Solenoid valve for charge pressure control - N75- Exhaust gas temperature transmitter 4 - G648-...
  • Page 326 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Charge air cooler pump - V188- ❑ Summary of compo‐ nents ⇒ “2.3 Summary of com‐...
  • Page 327 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1.1.3 Installation location overview - engine from right Note The Summary of components only concerns vehicles with engine identification characters CLHA, CLHB, CRKB, CKFB, CKFC, CUPA, CRMB, CUNA.

  • Page 328: Schematic Overview - Fuel System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ Summary of components ⇒ “3.1 Summary of components - exhaust temperature regulation”, page 402 ❑ electrical plug connection for lambda probe downstream of catalytic converter - G130- ⇒...

  • Page 329: Filling/Bleeding The Fuel System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Fuel filter ❑ Summary of compo‐ nents ⇒ “2.3 Fuel filter - Sum‐ mary of components”,...

  • Page 330: Check The Fuel System For Tightness

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 In order to fill up the high pressure pump with fuel, proceed as follows: • Vehicle must be refuelled.

  • Page 331: Injection Units/Fuel Distributor

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Injection units/fuel distributor ⇒ “2.1 Summary of components - injection units (injectors)”, page ⇒ “2.2 Fuel distributor - summary of components”, page 325 ⇒...
  • Page 332 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ fill/bleed fuel system af‐ ter exchange ⇒ “1.3 Filling/bleeding the fuel system”, page 321 7 - Clamping claw...

  • Page 333: Fuel Distributor - Summary Of Components

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Fuel distributor - summary of components 1 - Fuel pressure sender - G247- ❑ removing and installing ⇒ “4.6 Removing and in‐...

  • Page 334: Check Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Check injection units There are 3 ways to check the injection units. ♦ ⇒ “2.4 Adjust the correction values for injection units”, page 326 ♦...
  • Page 335 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Work procedure Note Safety precautions when working on the fuel supply system ♦ ⇒ “2 Safety instructions”, page 3 Observe rules for cleanliness ♦...
  • Page 336 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Pinch of coolant hose -arrow- using a hose clamp of up to 25 mm - MP7-602 (3094)- .

  • Page 337: Check Injection Unit Return Flow Quantity At Starter Speed

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Check injection unit return flow quantity at starter speed Note If the engine will not start the return flow quantity of the injection units can also be tested at starter speed.

  • Page 338: Carry Out The Vacuum Test Of The Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connection -2- at the fuel pressure control valve - N276- Pos. -1-. Note This prevents fuel from being injected during the start attempt.

  • Page 339: Removing And Installing The Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note Pay attention to cleanliness, no dirt must get into the fuel sys‐ ♦ tem. Check cylinders one after another.
  • Page 340 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Remove engine cover ⇒ “1.1 Removing and installing engine trim panel”, page 10 – Remove noise insulation.
  • Page 341 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screw -1- and remove clamping claws. • Order for injection unit expansion: First remove injection unit on cylinder “2”...

  • Page 342: Removing And Installing High Pressure Lines

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Replace the gasket ring for the injection channel, for this step use the assembly sleeve - T10377- .
  • Page 343 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screw -1-. – Unscrew union nuts -arrows- and remove high pressure line. 2.9.2 Installing high pressure line Special tools and workshop equipment required ♦...

  • Page 344: Removing And Installing The Fuel Distributor

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Caution Risk of line break because of high pressure line being under tension. ♦ Loosen fuel distributor and clamps for improved, tension- free positioning of injection lines.
  • Page 345 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Expose fuel return-flow hose -1-. – Open holding clamps -arrows-, unclip and remove cable duct -2-. – Disconnect electrical plug connections:...

  • Page 346: High Pressure Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 High pressure pump ⇒ “3.1 Summary of components - high pressure pump”, page 338 ⇒ “3.2 Removing and installing the high pressure pump”,...

  • Page 347: Removing And Installing The High Pressure Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ Re-adjust after replacing the learning values in “Targeted Functions” ⇒ Vehicle diagnostic tester 7 - Fuel intake hose...
  • Page 348 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Place counterholder - T10051- at the high pressure pump toothed belt pulley. – Tighten nuts -arrow- hand tight.
  • Page 349 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Mount the toothed belt pulley onto the hub. • There must not be any oil present between the counterholder and the toothed belt pulley –...

  • Page 350: Senders And Sensors

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Senders and sensors ⇒ “4.1 Removing and installing intake air temperature transmitter G42 / charge air temperature transmitter after charge air cooler G811 ”, page 342...

  • Page 351: Removing And Installing Air Flow Mass Meter G70

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Separate electrical plug connection -1-. – Unscrew fuel temperature transmitter - G81- -arrow-. Install Installation is performed in the reverse order, pay attention to the following points: –...

  • Page 352: Check Fuel Pressure Regulating Valve N276

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screw -1-. – Turn the air mass meter - G70- Pos. -2- in direction of arrow -B- and remove.
  • Page 353 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Work procedure Note Safety precautions when working on the fuel supply system ♦ ⇒ “2 Safety instructions”, page 3 Observe rules for cleanliness ♦...

  • Page 354: Replace Fuel Pressure Regulating Valve N276

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Replace fuel pressure regulating valve - N276- The fuel pressure regulating valve - N276- is located on the fuel distributor and provides a constant pressure in the fuel distributor and in the injection lines (fuel high pressure circuit).

  • Page 355: Removing And Installing Fuel Pressure Sender G247

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Separate electrical plug connection -2-. – Loosen union nuts -1- - to do so, hold on hexagon against the fuel distributor.

  • Page 356: Removing And Installing Differential Pressure Transmitter G505

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Before removing, clean the thread area around the fuel pres‐ sure sender - G247- with a grease remover (no dirt must get into the hole of the fuel distributor).

  • Page 357: Removing And Installing Pressure Sensor For Exhaust Gas 1 G450

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open heat protection sleeve -1-. – Separate electrical plug connection -4-. – Unscrew screw -3-, remove differential pressure transmitter - G505- from the holder.
  • Page 358 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open heat protection sleeve -1-. – Separate electrical plug connection -8-. – Unscrew screw -2-, lightly press the differential pressure trans‐...

  • Page 359: Lambda Probe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Lambda probe ⇒ “5.1 Lambda probe - Summary of components”, page 351 ⇒ “5.2 Removing and installing Lambda probe G39 ”, page 352 ⇒...

  • Page 360: Removing And Installing Lambda Probe G39

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 7 - Support 8 - Exhaust gas pressure sensor 1 - G450- ❑ only for vehicles with engine identification characters CRKB, CRMB, CUNA ❑...

  • Page 361: Removing And Installing Lambda Probe After Catalytic Converter G130

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew lambda probe - G39- -arrow- with extension (No. 22) - T10491- . Install Installation is performed in the reverse order, pay attention to the...
  • Page 362 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew the lambda probe after catalytic converter - G130- -arrow- with a socket wrench from the socket insert for lambda probe - 3337- .

  • Page 363: Intake Manifold, Air Filter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Intake manifold, air filter ⇒ “6.1 Assembly overview - intake manifold”, page 355 ⇒ “6.2 Removing and installing the throttle valve control unit J338 ”, page 357...
  • Page 364 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ 22 Nm 14 - Gasket ❑ replace after removal 15 - Inlet connections ❑ for throttle valve control unit - J338- 16 - Intake air temperature transmitter - G42- ❑...

  • Page 365: Removing And Installing The Throttle Valve Control Unit J338

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Intake manifold with charge air cooler - tightening torque and tightening order – Tighten screws in steps: Stage...
  • Page 366 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screw left and right -arrow-. – Unclip and remove bottom part -1- of air guide. – Unscrew screws -arrows-.

  • Page 367: Removing And Installing Intake Manifold

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screw -3-. Continued for all vehicles – Disconnect electrical plug connections: 2 - for Intake air temperature transmitter - G42- 3 - for throttle valve control unit - J338- –...
  • Page 368 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing Note Safety precautions when working on the fuel supply system ♦ ⇒ “2 Safety instructions”, page 3 Observe rules for cleanliness ♦...
  • Page 369 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unlock catch -arrow-, remove vacuum hose -1-. – Unscrew screw -3-, remove vacuum hose -2-. For vehicles with engine identification characters CRKB, CRMB, CUNA –...

  • Page 370: Summary Of Components - Air Filter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -10…1- with the Polydrive socket XZN 10 - T10501- , remove the intake manifold with charge air cooler.
  • Page 371 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Air deflector ❑ on the air filter lower part 2 - Screw ❑ 2 Nm 3 - Air guide lower part ❑...

  • Page 372: Removing And Installing Air Filter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing air filter Removing – Unscrew screws -1-, -3-. – Unlock catch -arrows-, remove cover-2-. – Expose coolant hose -2-.
  • Page 373 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect water drainage hose -arrow-. – Clean connection and air filter lower part and hose to remove dirt and leaves.

  • Page 374: Engine Control Unit

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Engine control unit ⇒ “7.1 Removing and installing engine control unit J623 ”, page 366 Removing and installing engine control unit - J623- ⇒...
  • Page 375 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note If the engine control unit is replaced, the must be ⇒ Vehicle ♦ diagnostic tester connected and the function “replace engine control unit”...
  • Page 376 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Heat the shear bolt head -1- for approximately 20 to 30 sec‐ onds. Continued for slackened screws –...

  • Page 377: Engine Noise Speaker

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Engine noise speaker ⇒ “8.1 Removing and installing engine noise speaker”, page 369 Removing and installing engine noise...

  • Page 378: Exhaust System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 26 – Exhaust system Removing and installing exhaust pipes/silencers ⇒ “1.1 Summary of components - front, middle and rear silencer”, page 370 ⇒...
  • Page 379 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Gasket ❑ replace after removal ❑ Check fitting position ⇒ page 372 2 - Clamping sleeve ❑...
  • Page 380 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ removing and installing ⇒ “1.4 Removing and installing rear silencer”, page 381 14 - Separation point ❑ for repairs ❑...

  • Page 381: Summary Of Components - Front, Middle And Rear Silencer, Vehicles With Front-Wheel Drive (Engine Identification Characters Ckfb, Ckfc, Crmb)

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1.1.2 Summary of components - front, middle and rear silencer, vehicles with front-wheel drive (engine identification characters CKFB, CKFC, CRMB) 1 - Gasket ❑...
  • Page 382 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ ustawienie układu wydechowego bez naprężeń ⇒ “1.6 Aligning exhaust system free of stress”, page 386 ❑ removing and installing ⇒...
  • Page 383 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Installation position of rear clamp – Install clamping sleeve in the angle position shown. • Angle -α- = approximately 30°.
  • Page 384 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 9 - Middle and rear silencer ❑ for first equipment a building unit, replace individually when carrying out repairs ⇒...

  • Page 385: Front, Middle And Rear Silencer, Vehicles With Eu4 Emis

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1.1.4 Front, middle and rear silencer, vehicles with EU4 emission level (engine identification characters CRVC) 1 - Gasket ❑...
  • Page 386 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 13 - Middle and rear silencer ❑ for first equipment a building unit, replace individually when carrying out repairs ⇒...

  • Page 387: Summary Of Components - Front, Middle And Rear Silencer, Vehicles With Four-Wheel Drive (Engine Identification Characters Clha, Ckfc, Crmb, Cuna)

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1.1.5 Summary of components - front, middle and rear silencer, vehicles with four- wheel drive (engine identification characters CLHA, CKFC, CRMB, CUNA) 1 - Gasket ❑...

  • Page 388: Removing And Installing Exhaust Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Installation position of gasket between exhaust gas cleaning mod‐ ule and pre-exhaust pipe • The square catch of the gasket -arrow- must be in the groove of the exhaust gas cleaning module.

  • Page 389: Removing And Installing The Exhaust Flap Control Unit J883

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screws -1-. – Slacken screw -2- and remove air filter housing. – Remove pre-exhaust pipe. Install...
  • Page 390 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 identification characters CLHA, CLHB, CRKB, CKFB, CKFC, CRVC, CRMB) Removing – Vehicles without separation point Replace middle or rear si‐...
  • Page 391 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen the clamping sleeve -2- and slide it forwards. – Unscrew screws -arrows-, remove middle silencer. Install...
  • Page 392 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen clamping sleeve -arrow- and press forwards. – Screw out screw -4- and remove rear silencer. If the exhaust pipe must be removed: –...

  • Page 393: Replacing Middle Or Rear Silencer

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screw -2-, remove middle silencer -1-. Install Install in the reverse order of removal. When doing this, note the following: –...

  • Page 394: Aligning Exhaust System Free Of Stress

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Note For vehicles with torsion beam rear axle, a disconnection is ♦ provided in the exhaust pipe to facilitate removal of the ex‐...

  • Page 395: Align Exhaust Tailpipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Push the rear silencer so far forward until the pre-tensioning on the retaining strap on the exhaust pipe is -a- = 5 mm.

  • Page 396: Cleansing Exhaust Emissions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Cleansing exhaust emissions ⇒ “2.1 Summary of components - exhaust gas cleaning”, page 388 ⇒ “2.2 Removing and installing exhaust gas cleaning module”, page 392 ⇒...
  • Page 397 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 7 - Radiator for exhaust gas recirculation ❑ removing and installing ⇒ “4.5 Removing and installing radiator for exhaust gas recirculation”, page 415 8 - Screw ❑...
  • Page 398 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 ❑ removing and installing ⇒ “2.2 Removing and installing exhaust gas cleaning module”, page 392 25 - Screw ❑...
  • Page 399 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 2.1.2 Summary of components exhaust gas cleaning (engine identification char‐ acters CRVC) 1 - Screw ❑ Tightening torque and tightening order ⇒...

  • Page 400: Removing And Installing Exhaust Gas Cleaning Module

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing exhaust gas cleaning module For vehicles with engine identification characters CLHA, CLHB, CRKB, CKFB, CKFC, CUPA, CRMB, CUNA...
  • Page 401 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 For engines with identification characters CLHA, CLHB, CKFB, CKFC, CUPA – Remove exhaust temperature transmitter -1- and -2- ⇒...
  • Page 402 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Disconnect electrical plug connections and lay the electric ca‐ bles to one side: for exhaust gas temperature transmitter 4 - G648-...
  • Page 403 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screw -3-. – Loosen hose clamps -1-, remove hoses. – Press out pipeline -2- and remove the differential pressure transmitter.
  • Page 404 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Push engine/gearbox assembly slightly forward (towards the front of the body) and then pull off the propshaft from the angle gearbox.
  • Page 405 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Open clamp -1- and position it on the flared opening of the exhaust gas cleaning module. – Unscrew the remaining screws in the order -4 … 2-.
  • Page 406 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Bring retaining lugs to the functional dimension using the cal‐ ibration tool - T10512- . – Slide the balancing element onto the firing pin, insert into the centring sleeve and turn the retaining lugs back by striking the ball stud lightly using the palm of your hand.
  • Page 407 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew balancing element (left-hand thread) -1- on the cyl‐ inder head using socket insert SW 8 - 3247- in -arrow direction- as far as the stop, then rotate a further 90°.

  • Page 408: Removing And Installing Catalytic Converter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Connect hoses, fit hose clamps -1-. – Tighten screw -3-, Pos. -4- ⇒ “1.6 Summary of components - toothed belt guard”, page 42 –...
  • Page 409 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew the screws -arrows- of the coolant line , pull the cool‐ ant line slightly to the front.

  • Page 410: Exhaust Temperature Regulation

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Exhaust temperature regulation ⇒ “3.1 Summary of components - exhaust temperature regula‐ tion”, page 402 ⇒ “3.2 Removing and installing exhaust gas temperature trans‐...

  • Page 411: Removing And Installing Exhaust Gas Temperature Transmitter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 4 - Exhaust gas temperature transmitter 2 - G448- ❑ only for vehicles with engine identification characters CRKB, CRMB, CUNA ❑...
  • Page 412 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing Note Fit all cable straps on again in the same place when installing. ♦ When removing, the electric cable must be not cut off, since ♦...
  • Page 413 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing Note Fit all cable straps on again in the same place when installing. ♦ When removing, the electric cable must be not cut off, since ♦...
  • Page 414 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 3.2.3 Removing and installing exhaust gas temperature transmitter 2 - G448- (en‐ gine identification characters CRKB, CRMB, CUNA) Special tools and workshop equipment required ♦...
  • Page 415 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 • The angled shaft -1- must point vertically upwards. – Electrical connections and proper routing ⇒ Electrical System;...

  • Page 416: Exhaust Gas Recirculation System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Exhaust gas recirculation system ⇒ “4.1 Exhaust gas recirculation with radiator for exhaust gas re‐ circulation - Summary of components”, page 408 ⇒...
  • Page 417 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Radiator for exhaust gas re‐ circulation ❑ removing and installing ⇒ “4.5 Removing and in‐ stalling radiator for ex‐...

  • Page 418: Exhaust Gas Recirculation With Radiator For Exhaust Gas Recirculation - Summary Of

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Installation position of air guide hose at radiator for exhaust gas recirculation Installation position for radiator for exhaust gas recirculation •...
  • Page 419 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 1 - Gasket ❑ replace after removal 2 - Connecting pipe ❑ to exhaust manifold 3 - Nut ❑...

  • Page 420: Control Motor For Exhaust Gas Recirculation V338 - Summary Of Components

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Tightening torques and -sequence holder for radiator for exhaust gas recirculation Stage Screws Tightening torque -2 ... 5-...

  • Page 421: Removing And Installing Control Motor For Exhaust Gas Recirculation V338

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing control motor for exhaust gas recirculation - V338- For vehicles with engine identification characters CRVC, CRKB,...
  • Page 422 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – if a vacuum hose is present: Remove it -arrow- and lay to the side. – Press release buttons on the hose -1- for crankcase ventila‐...

  • Page 423: Removing And Installing Radiator For Exhaust Gas Recirculation

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 Removing and installing radiator for ex‐ haust gas recirculation ⇒ “4.5.1 Removing and installing radiator for exhaust gas recir‐...
  • Page 424 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -arrows-, remove pulsation dampener -1-. Vehicles fitted with a manual gearbox – Remove switching and selector linkage from gearbox, un‐...
  • Page 425 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Mount hose -2- on radiator -1- for exhaust gas recirculation. • Fitting position: Marking “EGR side” -arrow- points to the ex‐...
  • Page 426 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Loosen hose clamp -1- and disconnect hose. Unscrew the nuts -arrows-. – For example, tie use coolant pipe with cable straps.
  • Page 427 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Unscrew screws -arrows- and carefully remove the radiator for exhaust gas recirculation -A- through the vehicle tunnel.

  • Page 428: Glow Plug System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 28 – Glow plug system Glow Plug System ⇒ “1.1 Summary of components - preheating system ”, page 420 ⇒...

  • Page 429: Removing And Installing Glow Plugs

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 6 - Sealing flange on the gearbox side ❑ removing and installing ⇒ “2.4 Removing and installing sealing flange on gearbox side”, page 66 7 - Rotor ❑...
  • Page 430 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Position pliers - 3314- using the sliding groove arrow -A- at the support sleeve collar arrow -B-, as shown in the illustration.

  • Page 431: Removing And Installing Automatic Glow Period Control Unit J179

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Place the glow plug connectors -1- back onto the glow plugs -arrows-. Note Make sure the glow plug connectors fit tightly.

  • Page 432: Removing And Installing Engine Speed Transmitter G28

    Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014 – Release screws -arrows-, push the right charge air pipe slight‐ ly to the side. – Separate electrical plug connection -2-.

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Octavia iii 2014

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